Napped fabric and process

ABSTRACT

A fabric having at least one hydraulically napped surface comprised of tangled fibers is disclosed. Because the fiber tangles are created from intact, undamaged fibers, fabric strength is not adversely affected by treatment. In addition, laundering enhances entanglement and the aesthetic qualities attributed to this fabric property: surface texture (hand), resistance to pilling, drapeability, and the like. These subjective characteristics have been quantified using values from the Kawabata Evaluation System. A process for creating such fabrics has also been disclosed. The fabric passes through one or two treatment zones in which high pressure fluids (e.g., water) are directed at the fabric surface as the fabric moves away from a support member. IN the case of dual treatment zones, a substantially lower pressure is used in the second treatment zone.

FIELD OF THE INVENTION

[0001] This invention relates generally to fabrics that have been nappedto yield physical and aesthetic properties that were previouslyunavailable. More particularly, in a preferred embodiment, thisinvention relates to woven fabrics of specific constructions that havebeen hydraulically napped in accordance with the teachings herein. Suchfabrics exhibit many highly desirable characteristics, such asrelatively high strength, an exceptionally soft and compliant hand, andother qualities that make such fabrics particularly well suited to usein a variety of applications, including use as napery fabrics, with theadditional important benefit that such qualities remain, and in somecases are significantly enhanced, after multiple washings.

BACKGROUND OF THE INVENTION

[0002] Practical methods for increasing the utility or desirability oftextile fabrics are constantly sought by the textile industry. Ofparticular interest are fabrics and processes that are developed for enduses that share a common set of physical or aesthetic requirements.Through the use of creative fabric constructions and fabric processingtechniques, fabrics that are especially well suited to specific end usescan be developed.

[0003] For example, the use of fabrics made from cotton or linen innapery (tablecloths, napkins, and the like) and related culinary orrestaurant applications (aprons, etc.) is well known—the combination ofhand, absorbency, drape, and other characteristics made these naturalfiber fabrics the traditional fabrics of choice. In recent years,however, fabrics made from synthetic fibers, with their durability,dimensional stability (resistance to wash shrinkage) and resistance toshade changes (due to staining or fading from repeated laundering), havedeveloped a strong following in the marketplace. These new fabrics,however, have not always shown clear superiority in several performanceareas that are of fundamental importance, such as hand, drape,resistance to pilling and snagging, and wicking (moisture transport).While such fabrics can be made soft and relatively pleasant to thetouch, the necessary conventional processing usually involves mechanicalnapping or sanding processes that tend to cut or damage fibers andthereby degrade the structural integrity of the fabric yarns and,ultimately, the overall strength and durability of the fabric.Furthermore, such processes can decrease moisture absorption andincrease the likelihood of snagging and pilling. Fabric constructions orfinishing processes that can impart superior drape and a soft,long-lasting feel to fabrics containing synthetic fibers without theseadditional shortcomings have been long sought.

[0004] Among the fabric processing techniques of the prior art that havebeen used in an attempt to achieve this result is the use of pressurizedstreams of water or other fluids. For example, commonly assigned U.S.Pat. No. 5,080,952 to Willbanks, the disclosure of which is herebyincorporated by reference, discloses a process for use with a polyesteror polyester/cotton woven fabric by which a nap is raised primarily fromwarp yarns, and to a lesser extent from the fill yarns, by means of ahydraulic napping process in which discrete streams of high velocitywater are directed onto the fabric as the fabric is held against a solidroll or other suitable support member.

[0005] Advantages of this, and perhaps other hydraulic napping processesof the prior art, as compared to conventional wire napping or sandingprocesses in which wires or abrasives are used to raise a nap or pilefrom the surface yarns, include the following: (1) the individual yarnscomprising the fabric are not cut or otherwise damaged, but instead aremerely rearranged (e.g., tangled) and extended from the plane of thefabric; (2) because of the lack of yarn damage, the strength of thefabric is not significantly impaired; (3) the nap raised tends to beuniform in height and density on the fabric side facing the roll; (4)because no shearing operation is needed, as would routinely be used forconventionally napped fabrics, fabric weight (per unit area) ispreserved and other properties such as cover (i.e., relative lightopacity) and absorbency can be enhanced as compared with fabrics thatrequire a shearing step; and (5) limited nap raising occurs on theopposite side of the fabric (that side facing the water streams),although not to the same extent as occurs on the side facing the roll,thereby imparting a napping effect to both sides of the fabric at thesame time, even though the streams impact one side only.

[0006] It has been found that, in spite of these advantages overconventional napping processes, these hydraulic processes of the priorart can affect the fabric in ways that are difficult to predict,resulting in non-uniform treatment and other processing shortcomings.

[0007] When the specific hydraulic napping process as described hereinis used in conjunction with a specifically engineered fabric, also asdescribed herein, the result is a fabric that displays a variety ofdesirable characteristics including high strength, high wash durability,color fastness, a soft and pliant hand with excellent subjective “feel”,superior wicking, and high resistance to pilling and snagging. It isbelieved that hydraulically napped fabrics possessing this uniquecombination of properties may be particularly desirable in many textilemarket areas, including, but not limited to, indoor and outdoor apparel,home furnishings (including shades and draperies, bed and table linens,upholstery fabrics, and toweling), and their commercial hospitalitycounterparts. One specific application in the commercial hospitalityarea to which fabrics of this invention have been found to beparticularly well suited is that of commercial napery. However, becauseof the high degree of superiority shown by the fabrics of this inventionin a variety of important fabric performance parameters, it iscontemplated that other market areas may also benefit from fabrics ofthe instant invention, even if one or more of the specific advantageslisted above are not of paramount importance in those markets.

DESCRIPTION OF THE DRAWINGS

[0008] The foregoing advantages of this invention, as well as others,will be discussed further in the following detailed description of theinvention, including the accompanying Figures, in which:

[0009]FIG. 1 is a schematic side view of an apparatus for practicing theinstant invention, wherein a continuous web of fabric is treated on asingle side of the web by an array of liquid jets;

[0010]FIG. 2 is a schematic side view of an apparatus for practicing theinstant invention, wherein a continuous web of fabric is treated on bothsides of the web by an array of liquid jets;

[0011]FIG. 3 is a perspective view of the high pressure manifoldassembly depicted in FIGS. 1 and 2;

[0012]FIG. 4 is a cross-sectional view of the assembly of FIG. 3,showing the path of the high velocity fluid through the manifold, andthe path of the substrate as it passes through the fluid stream beingprojected from the manifold assembly of FIG. 3;

[0013]FIGS. 5A and 5B are scanning electron photomicrographs (normalorientation—i.e., perpendicular to the fabric plane, at 27× and 50×,respectively) of the surface of a fabric of this invention comprised of100% synthetic fibers prior to treatment in accordance with theteachings herein;

[0014]FIGS. 6A and 6B are scanning electron photomicrographs (normalorientation, 27× and 50×, respectively) of the surface of the fabric ofFIGS. 5A and 5B following treatment in accordance with the teachingsherein and a single wash;

[0015]FIGS. 6Y and 6Z are scanning electron photomicrographs (normalorientation, 27× and 50×, respectively) of the surface of the treatedfabric of FIGS. 6A and 6B, following 75 washes;

[0016]FIGS. 7A and 7B are scanning electron photomicrographs (normalorientation, 28× and 50×, respectively) of the surface of a firstcompeting fabric, representing one embodiment of the prior art,following a single wash;

[0017]FIGS. 7Y and 7Z are scanning electron photomicrographs (normalorientation, 28× and 50×, respectively) of the surface of the fabric ofFIGS. 7A and 7B, following 75 washes;

[0018]FIGS. 8A and 8B are scanning electron photomicrographs (normalorientation, 28× and 50×, respectively) of the surface of a secondcompeting fabric, representing another embodiment of the prior art,following a single wash;

[0019]FIGS. 8Y and 8Z are scanning electron photomicrographs (normalorientation, 28× and 50×, respectively) of the surface of the fabric ofFIGS. 8A and 8B, following 75 washes;

[0020]FIGS. 9A and 9B are scanning electron photomicrographs (normalorientation, 27× and 50×, respectively) of the surface of a fabric ofthis invention comprised of synthetic and natural fibers, prior tohydraulic napping in accordance with the teachings herein;

[0021]FIGS. 9C and 9D are scanning electron photomicrographs (normalorientation, 27× and 50×, respectively) of the surface of the fabrics ofFIGS. 9A and 9B following treatment in accordance with the teachingsherein and a single wash; and

[0022]FIGS. 10A through 10C are graphs representing the results of a“co-occurrence” statistical analysis of the surfaces of the fabrics ofFIGS. 5 through 8, quantifying the degree of nap (or the relative ratioof disordered to ordered fibers) before and after multiple launderings.

DETAILED DESCRIPTION

[0023] In the detailed discussion that follows, the following termsshall have the indicated meanings. The term “synthetic fiber” shall meana man-made fiber, including, but not limited to, polyester, nylon,rayon, and acetate. The term “fiber loop” is intended to mean a segmentof an individual fiber that is spaced apart from, but remains attachedat both ends to, its associated yarn. The term “fiber tangle” isintended to mean a disordered arrangement of individual fiber loops,positioned above the surface of the fabric, that are associated with andconnected to, but that are spaced apart from, a fiber bundle. A fibertangle implies an arrangement in which the fiber loops are non-alignedand irregularly configured, but not necessarily entwined, interlocked orloosely knotted. A fiber tangle is primarily comprised of fiber loops,but may include free ends of fiber. The term “tangle cover” is intendedto mean the extent to which the fiber tangle associated with a givensurface yarn obscures from view the underlying fabric surface. The terms“napped” or “napping” as applied to fabric shall mean the raising offibers from one or more surface yarns to form a plurality of fibertangles that extend above the surface of the fabric and provide tanglecover. The term “surface yarn” is intended to mean that segment of ayarn comprising a fabric that forms a portion of the observed surface ofthe fabric, as viewed from a substantially normal (i.e., perpendicularto the plane of the fabric surface) perspective. The term “subsurfaceyarn” is intended to mean that segment of a yarn that is not a surfaceyarn (i.e., a subsurface yarn is hidden from view unless the fabric isreversed or seen in cross section). Using these definitions, a givenwarp or fill yarn in a woven fabric is considered to be comprised of acontiguous alternation of surface yarn segments and (where the yarndrops within or below the observed surface of the fabric) subsurfaceyarn segments. The term “observed surface fibers” is intended to meanthose fibers comprising a surface yarn that are readily observable whenviewed from a substantially normal (i.e., perpendicular to the plane ofthe fabric) perspective. The fabric side that faces the array of fluidstreams shall be termed the array side of the fabric; the side that isnearest to the supporting surface shall be termed the support side ofthe fabric.

[0024] Turning now to the drawings, FIG. 1 shows generally an apparatusthat can be used to produce the fabric of this invention wherein amoving web of fabric is treated on a single side only. Source 10 of thedesired working fluid, which shall hereinafter be assumed to be water,but which may be another suitable fluid as may be required or desiredunder the circumstances, is connected to high pressure pump 16 by meansof conduit 12. Use of a suitable filtering device 14 to remove particlesand other undesirable matter from the water is recommended. From pump16, the pressurized water is directed, via conduit 12, into stationarymanifold assembly 50, to be described in more detail below, in which thewater is formed into a plurality of discrete parallel streams that aredirected onto the surface of the moving web of fabric 30 to be treated.Fabric web 30 moves along a path that takes it into the regionimmediately adjacent to the stream-generating side of manifold assembly50 and into contact with a suitable support member, such as smooth steelroll 22, via roll 20. This region between the manifold and the supportmember through which the parallel streams of water are directed shall bereferred to as the treatment zone.

[0025] Within the treatment zone, but immediately prior to beingcontacted by water streams from manifold assembly 50, fabric web 30 isdirected away from roll 22, thereby providing a slight separationbetween the surface of support roll 22 and fabric web 30 as fabric web30 is impacted by the streams from manifold assembly 50. Specifically,the path of fabric web 30 elevates it off the surface of steel roll 22just prior to treatment by the individual water streams. In thepreferred embodiment depicted in FIGS. 1 and 2, the “thread up” path offabric web 30 describes a substantially straight line from a point oftangency, where fabric web 30 contacts support roll 22, at a locationimmediately upstream of the point of stream impingement, to the locationdownstream of the point of stream impingement where fabric web 30 isdirected in front of manifold assembly 50, although some deflection mayoccur during operation at the point of stream impingement.

[0026] The significance of this separation between fabric web 30 andsteel support roll 22 is in the role it plays in assisting in theefficient removal of water from the region within the treatment zonebetween fabric web 30 and the surface of support roll 22, which shall bereferred to as the roll impact zone. Support roll 22 preferably is madeto turn in the same direction that the fabric web is traveling withinthe treatment zone, and the entire manifold/roll assembly preferably isoriented so as to allow gravity to assist in the removal of water fromthe roll impact zone. This zone serves two important functions: itprovides a means by which water buildup can be relieved, yet alsoprovides a robust means of support for the fabric web 30 at the locationof impact by the individual water streams. By providing these twoseemingly contradictory functions, a high degree of uniformity in fabricweb treatment can be achieved. It should be understood that while use ofa steel roll as a support member has been described, a smooth solidplate or other means could be used, as desired.

[0027] It also frequently has been found advantageous to direct theindividual streams of water at an angle that is slightlynon-perpendicular, i.e., between about 1° and about 10° to the supportroll surface, and in a generally downward direction (i.e., in thedirection in which the spacing between the support roll and the movingfabric web is growing larger). In other words, as seen in FIG. 1, theplane containing the array of side-by side individual streams emanatingfrom manifold assembly 50 preferably does not contain the rotationalaxis of support roll 22. It is believed that this slight downward tiltto the water streams further minimizes the degree of water buildupbetween the fabric web and the roll, and further facilitates the removalof spent water from the roll impact zone. If left to accumulate withinthe treatment zone, such water buildup tends to interfere with theproper interaction between the impinging streams and the fabric surface.

[0028] Where a single treatment zone and relatively high streampressures are used, angles between about 2° and about 8° are preferred,and angles between about 4° and about 6° are particularly preferred. Ifa second treatment zone is used, as is discussed in detail below, thewater streams in the first treatment zone need not be inclined to thesame extent—angles between about 1° and about 50 may be used—because thelower water pressure associated with the second treatment zone resultsin reduced water flow, and therefore less water buildup.

[0029]FIG. 2 shows the apparatus of FIG. 1 that has been adapted totreat both sides of a moving web of fabric web in a single pass. In FIG.2, items corresponding to items in FIG. 1 carry similar identificationor call-out numbers, with the letters “A” and “B” used merely todifferentiate between that part of the apparatus used to treat one sideof the fabric web (Side “A”), and the corresponding part used to treatthe reverse side of the web (Side “B”). Water sources 10A and 10B supplywater to separate high pressure pumps 16A, 16B via suitable filteringmeans 14A, 14B. Fabric web 30 moves into operative position in front ofhigh pressure water jet manifolds 50A, 50B by means of variousconventional roll means, as shown. Support members 22A, 22B arepreferably rolls of steel or other suitable material having a smooth,solid surface. As discussed above, the point of water impingementcoincides with that portion of the fabric web path during which thefabric web is in tangential relation to the surface of the support roll,i.e., the support roll is no longer contacting the fabric web, butrather is acting as a point from which fabric web 30 is held in moderatetension as web 30 is directed past water jet manifolds 50A, 50B andthrough the water jet streams.

[0030]FIG. 3 is a cutaway view of manifold assembly 50, which is used inthe configurations of FIGS. 1 and 2, and shows the means by which anarray of high pressure water streams may be formed and directed onto themoving web of fabric. High pressure water from the interior of manifoldsupply conduit 52 is directed through a plurality of passages 60 toreservoir gallery 66, formed from juxtaposed reservoir chambers 64 and65 machined into chamber assembly 58 and gallery assembly 56,respectively (see FIG. 4). Cut into one of the mating surfaces ofslotted chamber assembly 58 is a series of parallel slots or grooves 68that, when chamber assembly 58 is mated to supply gallery assembly 56 bymeans of pressure bolts 70, form an array of parallel orifices 69, eachhaving a substantially rectangular cross-section, from which an array ofparallel streams of high pressure water can be directed on the movingweb of fabric 30.

[0031]FIG. 4 shows reservoir gallery 66 and related structures and theirrelation to moving fabric web 30. As indicated by the arrows, theworking fluid passes through passages 60 in gallery assembly 56 intoreservoir gallery 66 (FIG. 3) formed by reservoir chambers 64 and 65,which serves as a local distribution manifold for the orifices 69. Ascan be seen, fabric web 30 is guided, under tension, from support roll22 (FIGS. 1 and 2) onto the lower forward portion of supply galleryassembly 56 to position web 30 tangential to and slightly separated fromthe surface of roll 22. This allows the water to pass through the fabricweb without significant water buildup in the roll impact zone, and isbelieved to enhance the formation of a napped surface on the supportside of the fabric web (i.e., the side facing the roll).

[0032] To treat a single side of fabric web, pump 16 delivers the waterto manifold 50 at a pressure sufficient to generate a large number(perhaps several hundred or more) of discrete streams of water arrangedin an array, each stream having a rectangular cross section ranging fromabout 0.010 in.×0.015 in. to about 0.020 in.×0.025 in., with adjacentstream-to-stream spacing within the range of about 0.025 in. to about0.050 in. The manifold exit pressures depend upon the fabric web beingtreated and the desired effect. Pressures ranging from about 200p.s.i.g. to about 3000 p.s.i.g. are contemplated, with pressures betweenabout 500 p.s.i.g. and about 2000 p.s.i.g. most commonly employed, andpressures between about 1000 p.s.i.g. and about 1600 p.s.i.g. beingfavored for a wide variety of fabric web styles of the kind disclosedherein. The distance between the roll surface and the manifold may rangefrom about 0.030 in. to about 0.250 in., depending upon the nature ofthe fabric and the effect desired. Generally, roll-to-manifold-distancesof about 0.100 in. to about 0.200 in. are preferred. The fabric web ismoved past manifold assembly 50 at a rate between about 10 yards perminute and about 80 yards per minute, and preferably between about 25yards per minute and about 40 yards per minute, although speeds outsidethese ranges may be preferred with specific fabric webs and desiredeffects.

[0033] Where treatment on both sides of the fabric web is desired—atechnique that has been found to generate a remarkably uniform layer offiber tangles, in roughly equal amounts, on both sides of the fabricweb—the web should pass through a second treatment zone whereinpressurized water streams are directed at the opposite side of thefabric web, substantially as described above. The manifold exitpressures associated with the second treatment zone, however, arepreferably lower than the pressures associated with the first treatmentzone. Specifically, second treatment zone manifold pressures of about0.2 to about 0.8 times the pressures associated with the first treatmentzone have been found effective, with values between about 0.3 and about0.7 being preferred, and values between about 0.4 and about 0.6 beingmost preferred. Although these ratios may be modified somewhat if thewater pressures in the first treatment zone are extreme, it has beenfound that where second treatment zone manifold pressures fall outsidethese ratios, the side-over-side (i.e., array side vs. support side)uniformity of the napped surface is significantly degraded. It istheorized that fiber tangles that are generated within the firsttreatment zone are partially re-distributed through the fabric webwithin the second treatment zone, and relatively few additional fibertangles are generated within the second treatment zone. Accordingly,second treatment zone pressures that are too low appear to distributeinsufficient fibers to the reverse side, and second treatment zonepressures that are too high appear to distribute too many fibers to thereverse side.

[0034] The various photomicrographs of FIGS. 5 through 9 show thesurface of various fabric webs and graphically demonstrate the effectsand advantages of the instant invention. As summarized in Table 1, FIGS.5A, 5B show an untreated portion of the subject fabric of the invention.This fabric is subsequently treated and washed as described in Example 1and the accompanying FIGS. 6A, 6B. FIGS. 7A, 7B and 8A, 8B show firstand second fabrics, respectively, that are representative of currentlyavailable competitive napery fabrics, following one wash cycle asdescribed in Examples 2 and 3. FIGS. 6Y, 6Z; FIGS. 7Y, 7Z and FIGS. 8Y,8Z show, respectively, these same fabrics following 75 wash cycles, asdescribed in the respective Examples 5 through 7 below. FIGS. 9A through9D show the results of processing a blended fabric in accordance withthe teachings herein.

EXAMPLE 1

[0035] The following example describes how a superior napery fabric iscreated using a combination of fabric construction techniques andhigh-pressure water treatment. This particular fabric is 100% polyesterand is made of spun warp yarns and filament fill yarns. The fabric isconstructed as a plain weave and has 55 ends per inch and 44 picks perinch in the greige state. The warp yarn is an open end spun 12/1 (i.e. a12 singles cotton count yarn) with a twist multiple of 3.6, and thefilament filling yarn is a 2/150/34 (i.e. 2 plies of 150 denier yarn,each ply containing 34 filaments) and is an inherently low-shrinkagefilling yarn. The greige fabric without size weighs about 5.65 ouncesper square yard. Prior to hydraulic processing, the fabric is shown inFIGS. 5A and 5B. The above fabric is subjected to the followingprocessing. One side of the fabric is subjected to high-pressure waterat about 1400 p.s.i.g. (manifold exit pressure) The water originatesfrom a linear series of nozzles which are rectangular (0.015 inches wide(filling direction)×0.010 inches high (warp direction)) in shape and areequally spaced along the treatment zone. There are 40 nozzles per inchalong the width of the manifold. The fabric travels over a smoothstainless steel roll that is positioned 0.110 inches from the nozzles.The nozzles are directed downward about five degrees from perpendicular,and the water streams intersect the fabric path as the fabric is movingaway from the surface of the roll. The tension in the fabric within thefirst treatment zone is set at about 35 pounds.

[0036] In the second treatment zone, the opposite side of the fabric istreated with high-pressure water that originates from a similar seriesof nozzles as described above. In this zone the water pressure is about700 p.s.i.g., the gap between the nozzles and the treatment roll is0.160 inches, and the nozzles are directed downward about three degreesfrom perpendicular. As before, the water streams intersect the fabricpath as the fabric is moving away from the surface of the roll. Thefabric tension between the treatment zones is set at about 60 pounds,and the fabric exit tension is set at about 60 pounds. Maintenance ofthese specific tension levels is preferred, but is not necessarilycritical to achieve an acceptable result.

[0037] The fabric is dried and then subjected to a variety of finishingchemicals. It is pulled to the desired width in a tenter frame, and thefinished weight is about 6.25 ounces per square yard. Fabrics havingfinished weights between about 5 ounces per square yard and about 9ounces per square yard, and preferably between about 6 ounces per squareyard and about 8 ounces per square yard, and most preferably betweenabout 6 ounces per square yard and about 7 ounces per square yard, havebeen found to be particularly suitable in napery uses.

[0038] The fabric is then subjected to a single standard industrialwash, in accordance with the following procedure:

[0039] The fabric was loaded into an industrial washer (extractor Model30015) manufactured by Pellorin Milner Corp., of Kenner, La. Theequipment was verified to be free of burrs and sharp edges, to haveproperly functioning water level, temperature controls, and chemicaldelivery systems. Suggested Wash Formulas & Chemical Supplies forMilliken Napery WATER TEMPERATURE TIME CHEMICALS/ CYCLE LEVEL ° F.(Min.) 100 lbs. Flush High 120 3 Break Low 160 12  24 oz. Alkali 30 oz.Surfactant Carry-over Low 160 6 Rinse High 145 2 Rinse High 130 2 RinseHigh 115 2 Sour Low 90-100 8 2 oz. Sour Extract 5

[0040] The extraction time should be sufficient to permit the fabric tobe ironed without tumble drying. The fabric was removed from thelaundering unit and pressed (using a Model AE Air Edge Press,manufactured by New York Pressing Machinery Co. of New York, N.Y.) for atotal press cycle time of 20 seconds, consisting of 5 seconds of steam,10 seconds of bake (at 380° F.) and 5 seconds of vacuum.

[0041] The following wash chemicals were supplied by U.N.X. Incorporatedof Greenville, N.C.:

[0042] Alkali—Super Flo Kon NP

[0043] Surfactant—Flo SOL

[0044] Sour—Flo NEW

[0045] The results are as shown in FIGS. 6A and 6B and as described inTable 1. (Only one side of the fabric is shown; both sides of the fabricare substantially identical in terms of fiber entanglement, etc.) Thefabric surface shows a plurality of fiber tangles, each comprised offibers that are essentially intact and undamaged, i.e., the individualfibers show no nicks, dents, fibrillations, or other surfaceirregularities or deformities. The tangle cover is, in some cases,sufficiently dense so as to obscure from view the underlying fiberbundle to a significant degree.

EXAMPLE 2

[0046] A first competitive fabric is 100% polyester and has a spun warpand a spun filling. The fabric is constructed as a plain weave and has63 ends per inch and 47 picks per inch in the finished state. The warpyarn is an air spun 151 made of type T 510 polyester fiber (1.2 denierper filament×1.5 inches in length), and the filling yarn is an air spun151 made of type T 510 polyester (1.2 denier per filament×1.5 inches inlength). The finished fabric weighs 5.8 ounces per square yard.

[0047] The fabric is subjected to a single standard industrial wash, inaccordance with the wash procedure of Example 1. The result is as shownin FIGS. 7A and 7B and described in Table 1.

EXAMPLE 3

[0048] A second competitive fabric is 100% polyester and has a spun warpand a spun filling. The fabric is constructed as a plain weave and has67 ends per inch and 44 picks per inch in the finished state. The warpyarn is an air spun 11/1 made of type T 510 polyester fiber (1.2 denierper filament×1.5 inches in length), and the filling yarn is an air spun12/1 made of type T510 polyester (1.2 denier per filament×1.5 inches inlength). The finished fabric weighs 7.2 ounces per square yard.

[0049] The fabric is subjected to a single standard industrial wash, inaccordance with the wash procedure of Example 1. The result is as shownin FIGS. 8A and 8B and described in Table 1.

[0050] Although the Examples above have discussed only fabrics comprisedexclusively of synthetic fibers, it is contemplated that treated fabricscomprised of blends of synthetic and natural fibers should be includedas part of the instant invention. The following specific, non-limitingexample involves the use of a polyester and cotton blend in the warp ofa blended woven fabric, with either a blended or wholly synthetic fillyarn.

EXAMPLE 4

[0051] A blended fabric is comprised of a 65/35 blend of polyester andcotton made with a spun warp and a spun filling. The fabric isconstructed as a plain weave and has 102 ends per inch and 53 picks perinch in the finished state. The warp yarn is an open end spun 26/1,65/35 poly/cotton blend with a twist multiple of 3.69. The filling yarnis a ring spun 25/1, 65/35 poly/cotton blend with a twist multiple of3.80. The finished fabric weighs 4.25 ounces per square yard. FIGS. 9Aand 9B show the fabric surface prior to a hydraulic napping step asdescribed below.

[0052] The fabric is hydraulically napped as set forth in Example 1,above, except that the water pressure within the first treatment zone is1200 p.s.i.g., the spacing between the manifold and the support roll inthe first treatment zone is 0.120 inches, the speed of the fabric web is30 yards per minute, and the relative angle of the water jets is 0°.

[0053] The result is as shown in FIGS. 9C and 9D and described inTable 1. As can be seen, a profusion of fiber tangles has been createdabove the surface yarns that appear to be well distributed laterally,and the observed fiber tangles are not readily associated with warpyarns or fill yarns.

[0054] It is believed that the hydraulic napping action as describedherein is most effective, but not exclusively so, when the target fabriccontains yarns with staple fibers in significant quantities. The nappingaction is also most effective when those yarns are held within thetarget fabric structure in a way that allows the energy in theindividual water streams to displace, without damage or completeremoval, segments of the staple fibers, thereby forming a plurality offiber tangles comprised of disordered, but undamaged, staple fibersegments that remain attached at both ends to their respective yarns orfiber bundles. Generally, this has been found to occur most reliably inwoven fabrics where the staple fibers are contained in the warp yarns,or contained in both the warp and fill yarns.

[0055] An important characteristic and advantage of this invention isthe relative durability, following repeated washings, of the nappedsurface that is formed. This is believed to be due to the number offiber tangles that are generated initially, as well as the extent towhich the fibers are disordered within the fiber tangles, and theeffects that mechanical washing actions have on the fabric. Thiscombination of characteristics is believed to form a robust napstructure that not only successfully resists the rigors of repeatedlaunderings, but that tends to improve with such launderings—the degreeof distributional uniformity (i.e. lateral cover) and degree of disorderof the observed fiber tangles both appear to increase dramatically as aresult of repeated laundering, as compared with the nap surfaceimmediately following the hydraulic napping operation.

[0056] As a means to gauge the extent of this characteristic and assessthe magnitude of this advantage, the subject fabric of this invention asseen in FIGS. 6A, 6B and the commercially available competing naperyfabrics of FIGS. 7A, 7B and 8A, 8B were each subjected to 75 standardlaunderings and then examined by photomicrography. The details andresults of this comparison are the subject of Examples 5 through 7,below.

EXAMPLE 5

[0057] The fabric of Example 1 and shown in FIGS. 6A and 6B is washed(as described in Example 1) 75 times in succession. The surface of thefabric is as seen in FIGS. 6Y and 6Z, and as described in Table 1.

EXAMPLE 6

[0058] The fabric of Example 2 and shown in FIGS. 7A and 7B is washed(as described in Example 1) 75 times in succession. The surface of thefabric is as seen in FIGS. 7Y and 7Z, and as described in Table 1.

EXAMPLE 7

[0059] The fabric of Example 3 and shown in FIGS. 8A and 8B is washed(as described in Example 1) 75 times in succession. The surface of thefabric is as seen in FIGS. 8Y and 8Z, and as described in Table 1.

[0060] It should be noted that attempts to subject fabrics having a highcotton content typically do not survive 75 washes, due to degradation ofthe cotton fibers.

[0061] The following table summarizes some principal observations andcomments based upon the above-referenced photomicrographs. TABLE 1(PHOTOMICROGRAPH SUMMARY) Subject of FIG. Nos. PhotomicrographDescription Comments 5A, 5B Untreated subject fabric; Spun polyesterwarp is No fiber tangles outside normal (perpendicular) substantiallyconfined to yarn bundles view yarn bundle; filament fill is in orderlybundles 6A, 6B Treated subject fabric (1 Many localized fiber Treatmenthas partially wash); normal view tangles; distinct dislocatedsignificant checkerboard pattern numbers of staple fibers indicatesprimary from warp yarn bundles involvement of warp yarns 6Y, 6Z Treatedsubject fabric Dramatically increased Multiple washings have (75washes); normal number of fiber tangles enhanced treatment viewobliterating checkerboard effect 7A, 7B First competitive fabric Littleentanglement; no Fiber entanglements (1 wash); normal view distinctcheckerboarding quite isolated compared with treated subject fabric 7Y,7Z First competitive fabric Yarn bundles appear Multiple washings have(75 washes); normal more ordered; visible compacted or removed viewentangled fibers appear fiber tangles much more localized than after 1wash 8A, 8B Second competitive Limited fiber Fewer entanglements fabric(1 wash); normal entanglement; no distinct than subject fabric (FIG.view checkerboarding 6A, 6B) 8Y, 8Z Second competitive Slightly moreFiber entanglements fabric (75 washes); entanglement than after somewhatcompacted normal view 1^(st) wash; no checkerboarding 9A, 9B Treatedsubject blended Nominal occurrence of Individual fiber tangles fabricprior to hydraulic fiber tangles and are sparse napping; normal viewunattached fiber ends 9C, 9D Treated subject blended Widespreadoccurrence Treatment has partially fabric following hydraulic of fibertangles, well dislocated significant napping distributed laterally;numbers of staple fibers tangles not readily from surface yarnassociated with specific bundles warp or fill surface yarns

[0062] In an effort to quantify some of the distinctions and advantagesof the instant invention, a statistical technique generally referred toas “co-occurrence” analysis was performed, using the scanning electronmicroscope images of FIGS. 5A, 6A, 6Y, 7A, 7Y, 8A, and 8Y. Thesestatistics are derived from a “co-occurrence matrix.” The matrix issometimes called a concurrence matrix or second order histogram (Jain1989). The advantage of using this approach is the objectivequantification-of texture or degree of nap with a single number.

[0063] There is good correlation between the statistic referred to as“energy” in the References (see below) and the degree of nap. “Energy”is a general statistic for analyzing texture, and its value changes whenthe regularity of a texture changes. It is an unweighted average of thesquares of fundamental co-occurrence matrix values, and is therefore notbiased for any particular application. For convenience, this statisticshall be referred to as the “nap index” in FIGS. 10A through 10C.

[0064] The nap formed by the fiber tangles discussed herein covers upthe regular weave structure of the fabric, thereby essentiallyrandomizing the image. This leads to an decrease in the statistic,reflecting an increase in the degree of nap. The sign of the statisticwas changed for convenience, so that an increase in the degree of napresults in an increase in the value of the nap index.

[0065] The statistic was calculated for each sample from four SEMimages, formed by dividing the respective FIGS. 5A, 6A, 7A, and 8A eachinto quadrants, and treating each as a separate image. These repeatcalculations provide a measure of statistical variation. This variationis used as an estimate of statistical confidence. A 90% confidence level(two standard deviations) was used for the range of variation of thefour measurements for each sample. The two competitor samples did notinclude control samples (untreated fabric), and although all sampleswere plain weaves, the weave structures did not match exactly thecontrol sample of the subject fabric. Therefore, it is not possible tomake statistically meaningful comparisons among the various products.

[0066] The results of the measurements are graphically depicted in FIGS.10A through 10C. These results are fully consistent with subjectiveassessments made from visual examination of the photomicrographs, andare believed to support several conclusions. The subject fabric showssignificant nap following one wash. The degree of nap is substantiallyincreased after 75 washes, with a high degree of statistical confidence.This effect is totally absent from the results involving the first andsecond competitive fabric. The first competitive fabric shows, with ahigh degree of statistical confidence, a dramatic reduction in thedegree of nap following 75 washes. The second competitive fabric shows,at best, no statistically significant increase in the degree of napfollowing 75 washes. For a more thorough discussion of this technique,see one or more of the following References: (1) Robert M. Haralick, K.Shanmugam, Its'hak Dinstein, “Textural Features for ImageClassification,” IEEE Trans. Syst., Man, Cybernn., Vol. SMC-3, No. 6(1973), 610-621; (2) Robert M. Haralick, “Statistical and StructuralApproaches to Texture,” Proc. IEEE, Vol. 67, No. 5 (1979), 786-804; (3)Steven W. Zucker, Demetri Terzopoulos, “Finding Structure inCo-Occurrence”; (4) “Matrices for Texture Analysis,” Comput. Graph.Image Processing, Vol. 12 (1980), 286-308; (5) Anil K. Jain,“Fundamentals of Digital Image Processing,” Prentice Hall (1989),394-400.

[0067] In an effort to quantify further some of the aesthetic advantagesof the instant invention, selected measurements were made using theKawabata Evaluation System (“Kawabata System”). The Kawabata System wasdeveloped by Dr. Sueo Kawabata, Professor of Polymer Chemistry at KyotoUniversity in Japan, as a scientific means to measure, in an objectiveand reproducible way, the “hand” of textile fabrics. This is achieved bymeasuring basic mechanical properties that have been correlated withaesthetic properties relating to hand (e.g., smoothness, fullness,stiffness, softness, flexibility, and crispness), using a set of fourhighly specialized measuring devices that were developed specificallyfor use with the Kawabata System. These devices are as follows:

[0068] Kawabata Tensile and Shear Tester (KES FB1)

[0069] Kawabata Pure Bending Tester (KES FB2)

[0070] Kawabata Compression Tester (KES FB3)

[0071] Kawabata Surface Tester (KES FB4)

[0072] KES FB 1 through 3 are manufactured by the Kato Iron Works Co.,Ltd., Div. of Instrumentation, Kyoto, Japan. KES FB 4 (Kawabata SurfaceTester) is manufactured by the Kato Tekko Co., Ltd., Div. ofInstrumentation, Kyoto, Japan. The results reported herein required onlythe use of KES FB 2 through 4.

[0073] The mechanical properties that have been associated with theseaesthetic properties can be grouped into five basic categories forpurposes of Kawabata analysis: bending properties, surface properties(friction and roughness), compression properties, shearing properties,and tensile properties. Each of these categories, in turn, is comprisedof a group of related properties that can be separately measured. Forthe testing described herein, only parameters relating to the propertiesof surface, compression, and bending were used, as indicated in Table 2,below. TABLE 2 KAWABATA PARAMETERS AND UNITS Kawabata Test GroupKawabata Property and Definition Property Units Bending 2HB = Moment ofHysteresis Gms (force) cm/cm per unit length at 0.5 cm⁻¹ (is theopposite of recovery) Surface MIU = Coefficient of frictionDimensionless Compression LC = Linearity (ease of Dimensionlesscompressional deformation; similar to compressional modulus) DEN₅₀ =Density in g/cm³ based on Grams (force)/cm³ thickness at 50 gf/cm² COMP= Percent compressibility Percent based on difference in thicknessdivided by low pressure thickness

[0074] The complete Kawabata Evaluation System is installed and isavailable for fabric evaluations at several locations throughout theworld, including the following institutions in the U.S.A.:

[0075] North Carolina State University

[0076] College of Textiles

[0077] Dep't. of Textile Engineering Chemistry and Science

[0078] Centennial Campus

[0079] Raleigh, N.C.

[0080] Georgia Institute of Technology

[0081] School of Textile and Fiber Engineering

[0082] Atlanta, Ga.

[0083] The Philadelphia College of Textiles and Science

[0084] School of Textiles and Materials Science

[0085] Schoolhouse Lane and Henry Avenue

[0086] Philadelphia, Pa. 19144

[0087] Additional sites worldwide include The Textile Technology Center(Sainte-Hyacinthe, QC, Canada); The Swedish Institute for Fiber andPolymer Research (Mölndal, Sweden); and the University of ManchesterInstitute of Science and Technology (Manchester, England).

[0088] The Kawabata Evaluation System installed at the Textile TestingLaboratory at the Milliken Research Corporation, Spartanburg, S.C. wasused as a means to quantify some of the characteristics of the inventiondisclosed herein, and compare those characteristics with those of thefirst and second competing fabrics, as well as a cotton fabricrepresentative of fabrics commonly used in napery applications.

[0089] In each case, Kawabata testing was done following one industrialwash. The following fabrics were tested: First and Second CompetitiveFabrics: As described in Examples 2 and 3, respectively. 100% CottonFabric: A commercially available napery fabric having 74 ends and 58picks and a weight of 5.5 ounces per square yard Subject Fabrics 1-3:100% polyester spun warp napery fabrics having weights between 6.0 and7.0 ounces and various constructions, following hydraulic napping inaccordance with the teachings herein. Subject Fabrics 4 and 5: Twoexamples of the fabrics of Example 1, following hydraulic napping inaccordance with the teachings herein.

Kawabata Compression Test Procedure

[0090] An 8 inch×8 inch sample was cut from the web of fabric to betested. Care was taken to avoid folding, wrinkling, stressing, orotherwise handling the sample in a way that would deform the sample. Thedie used to cut the sample was aligned with the yarns in the fabric toimprove the accuracy of the measurements. Multiple samples of each typeof fabric were tested to improve the accuracy of the data.

[0091] The testing equipment was set-up according to the instructions inthe Kawabata Manual. The Kawabata Compression Tester (KES FB3) wasallowed to warm-up for at least 15 minutes before use. The gap intervalwas set according to the instructions in the Manual. Each sample wasplaced in the Compression Tester, and the plunger was lowered. The datawas automatically recorded on an XY plotter. The values of LC, DEN50,and COMP were extracted and averaged. The results are as indicated inTable 3.

Kawabata Surface Test Procedure

[0092] An 8-inch×8-inch sample was cut from the web of fabric to betested. Care was taken to avoid folding, wrinkling, stressing, orotherwise handling the sample in a way that would deform the sample. Thedie used to cut the sample was aligned with the yarns in the fabric toimprove the accuracy of the measurements. Multiple samples of each typeof fabric were tested to improve the accuracy of the data.

[0093] The testing equipment was set-up according to the instructions inthe Kawabata Manual. The Kawabata Surface Tester (KES FB4) was allowedto warm-up for at least 15 minutes before use. The proper weight wasselected for testing the samples. The samples were placed in the Testerand locked in place. Each sample was tested for friction, and the datawas printed as well as plotted on an XY recorder. The values of MIU weredetermined from the printed data and averaged. The results are asindicated in Table 3.

Kawabata Bending Test Procedure

[0094] An 8 inch×8 inch sample was cut from the web of fabric to betested. Care was taken to avoid folding, wrinkling, stressing, orotherwise handling the sample in a way that would deform the sample. Thedie used to cut the sample was aligned with the yarns in the fabric toimprove the accuracy of the measurements. Multiple samples of each typeof fabric were tested to improve the accuracy of the data.

[0095] The testing equipment was set-up according to the instructions inthe Kawabata Manual. The machine was allowed to wann-up for at least 15minutes before samples were tested. The amplifier sensitivity wascalibrated and zeroed as indicated in the Manual. The sample was mountedin the Kawabata Pure Bending Tester (KES FB2) so that the cloth showedsome resistance but was not too tight. The fabric was tested in both thewarp and fill directions, and the data was automatically recorded on anXY plotter. The value of 2HB for each sample was extracted from thechart and averaged. The results are as indicated in Table 3.

[0096] A table summarizing selected results of the KAWABATA testing isgiven below: TABLE 3 KAWABATA RESULTS LC DEN 50 COMP MIU 2HB Description(Compression) (Compression) (Compression) (Friction) (Bending) Firstcompetitive fabric 0.316 0.473 36.63 0.178 0.160 Second competitivefabric 0.251 0.498 40.20 0.179 0.229 100% Cotton 0.304 0.400 42.29 0.1810.147 Subject fabric (Sample 1) 0.359 0.394 37.49 0.185 0.190 Subjectfabric (Sample 2) 0.375 0.443 34.88 0.204 0.178 Subject fabric (Sample3) 0.387 0.407 33.10 0.200 0.171 Subject fabric (Sample 4) 0.425 0.37546.27 0.226 0.106 Subject fabric (Sample 5) 0.437 0.370 45.21 0.2190.094

[0097] As may be seen from the results of Table 3, the five subjectfabrics of the instant invention, and particularly those indicated as“Sample 4” and “Sample 5,” are indicated as being quantitativelysuperior in several aesthetically important ways to the other listedfabrics. Specifically, it has been determined that the uniqueness of thefabrics of this invention may be characterized in accordance with thefollowing individual Kawabata parameter values as follows: LC valuesgreater than 0.31, preferably greater than 0.375, more preferablygreater than 0.390, and most preferably greater than 0.410; DEN₅₀ valuesless than 0.400, and preferably less than 0.390, and most preferablyless than 0.380; MIU values greater than 0.195, and preferably greaterthan 0.200, and most preferably greater than 0.215; COMP values greaterthan 42.5, and preferably greater than 44.0, and most preferably greaterthan 45.0; and, lastly, 2HB values that are less than 0.200, andpreferably less than 0.140, more preferably less than 0.130, and mostpreferably less than 0.120. It should be understood that, because of thetendency for some properties of the fabrics of this invention to bemutually exclusive, the fabrics of this invention are not alwayscharacterized by values of any single Kawabata measurement, but ratherby the combination of values of two or more Kawabata measurements.

[0098] Having described the principles of my invention in the form ofthe foregoing exemplary embodiments and non-limiting Examples, it shouldbe understood by those skilled in the art that the invention can bemodified in arrangement and detail without departing from suchprinciples, and that all such modifications falling within the spiritand scope of the following claims are intended to be protectedhereunder.

We claim:
 1. A fabric having a hydraulically napped surface comprised ofa plurality of fiber tangles, said fiber tangles being comprised offibers that are substantially intact and undamaged, said fabric having aKawabata System MIU value greater than 0.20.
 2. A fabric having ahydraulically napped surface comprised of a plurality of fiber tangles,said fiber tangles being comprised of fibers that are substantiallyintact and undamaged, said fabric having a Kawabata System LC valuegreater than 0.375 and an MIU value greater than 0.195.
 3. The fabric ofclaim 2 wherein said fabric has a Kawabata System LC value greater than0.390 and an MIU value greater than 0.21.
 4. The fabric of claim 2 or 3wherein said fabric is a woven fabric having warp yarns and fill yarnsand said napped surface is comprised of fibers from said warp yarns. 5.The fabric of claim 4, wherein said warp yarns are comprised ofsynthetic fibers.
 6. The fabric of claim 4 wherein said warp yarns arecomprised of spun polyester yarns.
 7. The fabric of claim 4, wherein themajority of said fibers comprising said fiber tangles are from said warpyarns.
 8. The fabric of claim 5 wherein said fabric has a nap index thatincreases with repeated launderings.
 9. A fabric having a hydraulicallynapped surface comprised of a plurality of fiber tangles, said fibertangles being comprised of fibers that are substantially intact andundamaged, said fabric having a Kawabata System DEN₅₀ value less than0.40 and an MIU value greater than 0.195.
 10. The fabric of claim 7wherein said fabric has a Kawabata System DENS value less than 0.39 andan MIU value greater than 0.21.
 11. The fabric of claim 8 or 9 whereinsaid fabric is a woven fabric having warp yarns and fill yarns and saidnapped surface is comprised of fibers from said warp yarns.
 12. Thefabric of claim 10, wherein said warp yarns are comprised of syntheticfibers.
 13. The fabric of claim 10 wherein said warp yarns are comprisedof spun polyester yarns.
 14. The fabric of claim 10 wherein the majorityof said fibers comprising said fiber tangles are from said warp yarns.15. The fabric of claim 12 wherein said fabric has a nap index thatincreases with repeated launderings.
 16. A fabric having a hydraulicallynapped surface comprised of a plurality of fiber tangles, said fibertangles being comprised of fibers that are substantially intact andundamaged, said fabric having a Kawabata System 2HB value less than0.130 and an MIU value greater than 0.195.
 17. The fabric of claim 16wherein said fabric has a Kawabata System 2HB value less than 0.130 andan MIU value greater than 0.21.
 18. The fabric of claim 16 or 17 whereinsaid fabric is a woven fabric having warp yarns and fill yarns and saidnapped surface is comprised of fibers from said warp yarns.
 19. Thefabric of claim 18, wherein said warp yarns are comprised of syntheticfibers.
 20. The fabric of claim 18 wherein said warp yarns are comprisedof spun polyester yarns.
 21. The fabric of claim 18, wherein themajority of said fibers comprising said fiber tangles are from said warpyarns.
 22. The fabric of claim 19 wherein said fabric has a nap indexthat increases with repeated launderings.
 23. A fabric having ahydraulically napped surface comprised of a plurality of fiber tangles,said fiber tangles being comprised of fibers that are substantiallyintact and undamaged, said fabric having a Kawabata System 2HB valueless than 0.130 and a COMP value greater than 42.5.
 24. The fabric ofclaim 23 wherein said fabric has a Kawabata System 2HB value less than0.130 and a COMP value greater than 44.0.
 25. The fabric of claim 23 or24 wherein said fabric is a woven fabric having warp yarns and fillyarns and said napped surface is comprised of fibers from said warpyarns.
 26. The fabric of claim 25 wherein said warp yarns are comprisedof synthetic fibers.
 27. The fabric of claim 25 wherein said warp yarnsare comprised of spun polyester yarns.
 28. The fabric of claim 25,wherein the majority of said fibers comprising said fiber tangles arefrom said warp yarns.
 29. The fabric of claim 26 wherein said fabric hasa nap index that increases with repeated launderings.
 30. A woven naperyfabric comprised of spun warp yarns and filament fill yarns and having ahydraulically napped surface, said warp yarns and said fill yarnsconsisting essentially of intact, undamaged fibers, said napped surfacebeing comprised of a plurality of fiber tangles from said warp yarns.31. The napery fabric of claim 30 wherein said filament fill yarns arelow shrinkage yarns.
 32. The napery fabric of claim 30 wherein said spunwarp yarns are comprised of synthetic fibers.
 33. The napery fabric ofclaim 30 wherein said spun yarns are comprised of polyester fibers. 34.The napery fabric of claim 30 wherein said spun yarns consist ofpolyester fibers and wherein said fabric has a nap index that increaseswith repeated launderings.
 35. A process for forming a napped fabricwherein said fabric passes through a treatment zone in which a pluralityof individual streams of high pressure fluid is directed onto saidfabric, said process comprising the steps of (a) directing said fabricagainst a support member having a support surface as said fabric enterssaid treatment zone, (b) directing said fabric away from said supportsurface as said fabric moves through said treatment zone, and (c)directing said plurality of individual streams onto said fabric as saidfabric is leaving said treatment zone and is moving away from saidsupport surface, thereby forming on said fabric a napped surface, saidsurface being adjacent to said support surface.
 36. A process forforming a napped surface on both a first and a second side of a wovenfabric, said fabric being comprised of yarns containing staple fibers,said process comprising the steps of moving said fabric along a path inwhich said fabric passes through a first treatment zone wherein aplurality of individual streams of high pressure fluid is directed ontosaid first side of said fabric, whereby said fluid streams arrange saidstaple fibers to form a napped surface comprised of fiber tangles onsaid second side of said fabric, and then moving said fabric along saidpath wherein said fabric passes through a second treatment zone whereina plurality of individual streams of high pressure fluid is directedonto said second side of said fabric, whereby said fluid streamspartially redistribute said fiber tangles from said second side of saidfabric to said first side of said fabric, wherein said fluid streams insaid second treatment zone directed at said second side have a pressurethat is substantially less than the pressure of said fluid streams insaid first treatment zone directed at said first side.
 37. The processof claim 36 wherein the pressure of said fluid streams in said secondtreatment zone is less than the pressure of said fluid jets in saidfirst treatment zone by a factor that is greater than about 0.2 and lessthan about 0.8.
 38. The process of claim 36 wherein the pressure of saidfluid streams in said second treatment zone is less than the pressure ofsaid fluid streams in said first treatment zone by a factor that isgreater than about 0.4 and less than about 0.6.
 39. The process of claim36 wherein said path directs said fabric against a support member havinga support surface as said fabric enters one of said treatment zones, andthen directs said fabric away from said support surface within said oneof said treatment zones.
 40. The process of claim 36 wherein said pathdirects said fabric against a support member having a support surface assaid fabric enters each of said treatment zones, and then directs saidfabric away from said support surface within said each of said treatmentzones.
 41. The process of claim 36 wherein said napped surface formed bysaid fiber tangles is substantially uniform on both said first side andsaid second side.